Method of extracting metal values from ores.



PATENTED OCT. 9. 1906.

, R. BAGGALEY. METHOD OF BXTRACTING METAL VALUES FROM ORES.

APPLICATION FILED. DBO. 4. 1905.

7 SHEETSSHEET 1.

lnmlmlllmlii l m all WITNESSES 1 m W PATENTED OCT. 9, 1906.

APPLIOATION FILED DEO.-4. 1905.

'7 SHEETS-SHEET 2 7 SHEETS-SHEBT 3 VII!!! IflhfI/llllllf INVENT R PATENTED OCT. 9, 1906.

R. BAGGALEY.

METHOD OF EXTRAGTING MIBTAIQ VALUES FROM ORES. APPLICATION FILED DEC. 4. 1905.

V wn'nsssss No. 832,833. I PATENTED OCT. 9, 1906. R. BAGGALEY. METHOD OF EXTRAGTING METAL VALUES FROM ORES.

APPLICATION FILED 1130.4. 1905. I

SHEETS-SHEET 4.

WITNESSES INVENTOR No. 832,833. PATENTED OCT. 9, '1906. R. BAGGALEY. METHOD OF EXTRACTING METAL VALUES FROM ORES.

APPLICATION FILED DEQQ. 1905.

7 SHEETS-SHEET 5.

No; 332,333. PATENTED 00 1?. 9, 1906.

R. BAGGALEY. METHOD OF EXTRAGTING METAL VALUES FROM 0333.

APPLICATION FILED 10110.4. 1905.

7 SHEETS-SHEET 6.

WITNESSES INVENTOR No. 832,833, PATENTED OCT. 9, I906.

R. BAGGALEY. METHOD OF EXTRACTING METAL VALUES FROM ORES. APPLICATION FILED 12110.4. 1905.

7 SHEETSQSHEET 1. 1

WITNESSES INVENTOR RALPH BAGGALEY, OF rir'rseune, PENNSYLVANI -METHOD oFExTnAcTmc. M TAL VALUES FROM oREs.

T all". whom it may concern:

Be it known that I, RALPH BAGGALEY, of Pittsburg, Allegheny county, Pennsylvania, have invented a new and useful Method of Extracting Metal Values from Ores, of which I the following is a full, clear, and exact dethe ore, and

scription, reference being had to the accoming drawings, forming part ofthis specification, in -which p Figure 1 illustrates a longitudinal section on the line I I of Fig. 2 of my preferred form of apparatus for practicing the invention. Fig. 2 illustrates a crosssection on the line II II of Fig. .1. Fig. 3 illustrates a cross-section on the line III III-of Fig. 1. Fig. 4 is a vertical longitudinal section showing my alternate form of apparatus, in which the converter is fixed and is not rotary, as in the previous figures. Fig. 5 is a vertical cross-section, on a larger scale, on'the line V V of Fig. 4. Fig. 6 is a side elevation showing the device which I on the line VII VII of Fig. 6.

My invention provides a method by which to successfully perform a new, process of simultaneously smelting and extracting values by liquation or sweating from a large proportion of ores in which actual fusion is notnecessary to extract the values. This result is cheaply accomplished because the use of carbonaceous fuel is unnecessary. It renders available for commercial use vast bodies of low-grade ores that are now worthless.

To start the process, it is necessary to provide a bath'of molten matte, preferably derived from an outside source, although, if preferred, it may be melted within the vessel itself. It should be sufficient to fill the vessel with matte up to the level of the over flow-spout, and it is preferably'derived from a simple melting with the least possible concentration of ores that are rich in iron, sulfur, and other oxidizable elements and com pounds. A converting-blast-is then driven into the bath ,of molten matte, which produces heat, and thereafter ores are fed into the apparatus eithercontinuously or inter- 'gnittently, as may be preferred. If in creased heat is desired in the bath, sulfids are fed.

If mineral values are desired, these are usually best obtainable from ores of a sili-' Care should be taken to procious nature. vide and maintain a molten bath that con. tains sufiicient iron, sulfur, and other oxidizable 'elements and compounds to con- Specification of Letters Patent.

submerged or partially submerged in prefer to employ for preheating ig; 7 is a vertical cross-section Patented Oct. 9, 1906.

Application filed December 4, 1905. Serial No. 290,095.

stantlysupply the heat necessary to produce success.

the furnace, and these are fused to the point where the iron in'the matte after oxidation will form Thereafter silicious ores are fed into p selective slag at minimum temperathereafter an excess of silicious ores may be fed onto the molten bath, and these float matte the entire length of the vessel, subjected to the heat and the agitation produced by. a converting-blast, so that their mineral contents, usually existing in the form of occluded particles of sulfid, are sweated out, join the molten bath of matte, and are recovered, while the liquated worthless silicious" shells are discharged with slag and matte into the forehearth at a lower level.

In the latter vessel 'the matte-prills are very thoroughly separated from the worthless slag and. silicious-ore shells under favorable conditions that guarantee an excellent-recovery.

The liquating or-sweating out of mineralfrom various cupreous materials is not a new art in metallurgy, if carbonaceous fuel be utilized to produce and-tomaintain the necessary heat. It is, however, radically new and is'much more economical to practice the liquation in the apparatus described in my present invention inwhich' no carbonaceous fuel is used. In using erably crush the ores to a small size-say'to the size of a walnut-preheat them to a temperature less than that at which sulfid fuses, and deliver them into the furnace, as illustrated in the drawings. for the thorough recovery of their contained values, preferably as described in United States Patent No. 766,654, issued August 2,

1904, in application Serial No. 235,418, filed December 5, 1904, or in other ways. Converter-slags may also be delivered into this apparatuses a thorough, quick, and economical means of extracting their contained mineral values.

this apparatus I pref-.

My preferred apparatus, as shown in Figs.

1, 2, an 3, comprises a converter which is rotatably' ounted, referably upon rollers or a cradle, and is pre erably made'of cylindrical form of greater length than diameter. As above stated, this furnace is mounted on rollers 3 3 and has an exterior metal shell 4 and an interior refractory lining '5, the metal shell being preferably provided with watercooling pipes 6, through which streams of The fines I treat. I

water are maintained for the purpose of placthe lowest point of the converter and passes upwardly therefrom, and thence discharges into elevated mains 8 8,-thus preventing the possibility of the formation of steam-pockets. The converter 2 is provided with a throat 9 for the escape of gases, and this throat communicateswith a telescopic pipe 10, through which the .gasespass to astack. The lower .s'ection of the,pipe l'Oispreferably provided doors 11 to afi'ord means for removing congealedslag from the interior of the throat .9. During the operation of the converter the lowestsection of the telescopic pi e is pref sidera which .tl16.,Sl1 fi S 0f thefore can be'iused When itjis not, desired to' pass the gases from the converter through the preheater,; they can be diverted directlythrough the dust- V matte. 'This has the effect of conserving the heat-to a muchgreateifdegree' than-exists in i presentpraotice, it causes an exceptionally clean se be ming ed with'the slag; and,- owing to the erably dropped into position upon t e throat 9, as shown in Fig. 1, so as to exclude theair,

and thus prevent any, cooling influence upon the .hot gases of the converter.- These gases may thence be led. to a suitable preheater, in which the crate 'be charged into the con- .verterlnfliy be heated to a point less'lthan the This preheating has the efiectjot expelling moisture from the ores and alsoheats them to an important extent, thus, materially increasing the smelting caacity of the converter, The preheater, iioweyenneed not be used', and in such ease the gasesmaybe led directly into dust-chamhers, in which the" dust, oftenrith in metal values, may, be collec te( l. Ifillustrate such reheaterili Fig.6, inwhich 12 represents a ollowwchamber, into which the gase s disohargeifrom theconverter. This chamber is of. considerablelength and contains two subchambers13 14, one above the other, in which the branches ,of ,an.e dless chain extend, this endless.cl1am ,15, passing around sprockets 16 andhavinglstirriersfl for propelling the ore.

The. ,ore is introduced into the r pper chamber ficient matte and' 'sla have accumulated-to fill the foreheartli tothe top l'evel,- a clay 14 through. a-jeeding device 18 and is' carried direction of thelower arrow to a second drop v20, at whichjitt drops into: the;feed-tube 21,"

which leads to. the Col lyerter. Thegases ore-is; assing,v and thus heatthe ore to a conletem erature, hut'short off-that at chamber .22 into. the stack-flue. -The flue- .dust. from the. dust-catcher 22 may he re Hmoved from time totime through openings 2 3uat itsbasei v .t t

The converter 1s preferably about twenty throughs'uchfihamber in the directionj'of the rrow bytthe endless chain until it comes to a .drop 19, where it drops 'intothe lower chambe; 13 ,aiidis there engaged againby the stirrers on the endlesschain'and is carried in the I feet in length and eight feet in diameter. At one end, as above stated, it is provided with the pipe 21, through which ore is-introduced, and with adjacent openings 24, through which molten matte may be introduced. At

the other end of the furnace is the outlet 9 for the gases and an overflow-spout 25 for the escape of the molten matte and the slag and silioious shells. This spout 25 is preferably water-jacketed, as the volume of material 4 that passes through itis very great and it is desirable to Water-jacket it in order to prevent injury by reason of the cutting action of the flowing material. 26 is a practically airtight metal drop tube, through which the molten slag and matte 'and'the silicious shells flow together out of the overflow-spout into the forehearth-27. The drop tiihe 26 isproyided with an opening 28, through which the overflow-spout may be'w'atched by thejoperator, and when'hecessary maybe quickly and thoroughly rodded. This o'p'eriing affords imeans for raking out and dropping into the forehearth any chilled accretions' that may form." It is' provided with a'heavy metal .door which 'may be of any convenient size and is prefie'rably'in the form of a circle, so that it may be rolled to' one side for the purpose of opening- By reason of the use oflthe open overflow-spout 25'thelevel of'the bath in the converter is limited, and the'forehearth.

affords a'free c'lisohargefor'the sla 'and shells and prevents any trapping of the hlast, such as prevails in ordinary blast fiirnac'e' practice, an 100 v i also prevents the accumulation of a body of floating slag whichalways exists in any 'form of' apparatus in 'whichthe' bl'astis trapped.

29 represents" congealed slag-covering,

which forms over the forehear'th and constitutes a practically air-tight u'u'ioi at 30 with the metaldr'op-thbe 26. "Wh'en'the operation of the converter is start'ed and when sutplu ior dani preferably placed in the slagdisc harge 31 of the forehearth, and after the chilled covering 29 has. been formed this clay dam is removed "and the 'ov'e'rflowingfslag then finds a ready outlet to'the slag-pot 32 or dition [and ,for the floating liquated ore throughthe 'fo'rehearth and underneath the congealed'slag-covering, in'ojr'de'r" thu s'to se- 4 cure a further separation of all mineral and arat ion or all matte-'pi'ills that may the vessel.

1ron,. sulfur, and other oxidizable fluxingwith the iron, and

saassa intense heat and the consequent fluidity of' op-. portunity for sweating or liquation under favorable conditions.v When ultimately discharged from the forehearth, both the molten slag and the floating silica lumps are exceptionally clean.

A bridge 33 is preferably placed over the forehearth in order to afford a platform on which the workmen may Work.' Owing to the differences which characterize my process from those heretofore practiced, this bridge is almost a necessity, because the corrosive nature of the matte in the forehearth is such that it eats away the slag covering and renders it too frail for the workmen with safety to stand upon it, as is the casein ordinary practice.

he. converter is provided with twyers 34,.

The confed from a suitable wind-box 35. verter is also provided with suitable means (shown at 36 and 37 in Fig. l)-for rotating it on the rollers 3 3.

it is that in case of sired to empty thecontents of the converter, this may be done by lifting thettelesc'opic section 21 at the base 'of the pipe 21 and the telescopic section at't'he base of the outlet for the gases and then inverting the converter and discharging its molten contents, thus preventing the The molten contents of the forehearth should be tapped out at the same time in such event, since otherwise its contents would also solidify and would have to sumed'.

In the use of'the apparatus a bath of mollten matte is provided in the vessel, as above stated, this matte being preferably of low grade and preferably not exceedingtwenty per cent. in values. Such bath is rich in elements and compounds and is necessarily very hot, liquid fiend corrosive. I When this been formed, air is blown into it through the twyers 34-andf. silicious ore is introduced through the .opening 21. upon the matte, part of it will be taken upby the remainder will be cracked by the heat and will yield up its metal values to the bath. 1 .This action isv due to the fact that the temperature of the molten baththe' temperature which must al'- to keep-it molten+is Ways exist in order greatly in excess of the constituents of the ore, are freed by fusion from the ore when the freed nature are quite-diiferent The purpose of rotating accident, when it is de' its The rate of feed may be regulated as desired.

same from freezing in converter are at a considerable ,which is desirable bath has This ore will float feet'in length, whereas ,paratus about twenty "sents the practical 'iimit. ,st'ack-flue 10 leads out of fusing-point of the rejctlyabove the overflow-spout so that 1 sulfur containedintheore and is also in eX-'f cess of the most difficultly-fusible sulfid constituent of. the ore and is greater'than the" above lthe level heat, and being thus become a part of the latter is cracked by the they pass into and molten bath, while the Worthless silicious shells remain unfused and pass off'with the slags into the forehearth. The greater the length of the apparatusthe longer Will be the travel of the floating ore immersed in the bath from the point of entrance at one end to the pointof discharge through the overflowspout at the other end. Ores as found in physically. Some will yield up their values by liquation more quickly than-others. The length of the vessel must be governed by thecharacteristics of the ores to be treated. The latter should remain in the bath for a long enough period 'to have their occluded minerals separated from the gangue, 'so that they will. join themolten bath of matte before the worthless silicious shells are discharged into the forehearth; otherwise a useless waste of values will occur. The difference in characteristics of the ores, therefore, must regulate their soourn in the molten bath,'land thissojourn can alone be governed by the length of the furnace and the rate of feed. 1t will be found cheaper in practice to increase the producing capacity by checking the feed.

Within certain limits a long travel for the floating ore-is desirable; but no good can result from making this travel greater than is found in practice to accomplish a clean separation. The s'ize of the vessel will govern the volume of initial bath,whichmust cover the converting-twyers to start the process. An

adequate volume of blast must-also be provided. 1 In the use of the apparatus the gases in the pressure, because it -helps to main tain the high temperature in the converter necessary for carrying out the process. I Be cause ,of the pressure openings of; the converter, such as the joint at the pipes 10 and 21 and also the moltenslagcharging opening 24, should be'tightly closed.

In the modified construction of apparatus shownin' Figs. 4 and 5 the converter is stationary and is designed for use where a greater length is desired. I Being stationary, it may conveniently be made of forty oreven sixty with the rotatable ape [n this casethe the converter dithe whole discharging end of the converter of the bath is open to the stack] As the vessel shown in Figs. 4 and 5 cannot be tipped for the purpose of dischargmg the molten contents, 1 provide a tap hole 38 atthe end and at its lower level. Attenlength of the furnace rather than to reduce of the gases the several feet'in length repretion jscalledtoitheifact-that-where the ap),

H ratus is fixed :the .twyers must be-provi ed with metal plugs in order ttoapre'vent them from filling with congealed matte when the blastfrom anylcauseis-shut. oil- *l/Vithinthe scope ofmny invention asdefined in ;the claimswhesteps of the process may be {modified and apparatus .of other formsmay be used ,since What lclaimis- 1. Theimethodof extractingmetal values cious. ore ,toga'bath of moltenmatte in excess ofithe amount'lth at will flux with the. comauents. Qfithebath, \andcausing the excess portions of the-ore {to yield their values to the bathibyliquation substantially as described.

2. Themethod of extractingmetal values trom ores through liquation without .carbonaceous fuel, {which I consists in feeding silicious ore .to abath otmeltemmatte in. excess ofthe amount that will tfiux-with the constituents of-the lbath, blowingair intothe bath, and. causing the excess portions of the oreto .y'deld their values to -the bath :by liquation; substantiallyasdescribed.

. 3. Hlhe method of. extracting "metal values from ores sthrough ,liquation without carboinaeeeus fnel, which consists in feeding siliciousores toaxmoltenbath o'tmatte at a temperatureiwhichkwillfluxa;;portionof thesilica .of, the lore with {the iron of the matte, .but

which will-leave unfused the residual andv-unfluxedmortionscf the ore whereby such unfluxe'd portions of the ore arecaused to yield their values to the bath by 'liquation; sub"- stantially as described.

:4. The .methodhot extracting metal values from silicious ores which consists in feeding such ore into a molten bath .of matte, extracting values -iromthe ore and permitting the residue of the ore while subjected to the heat etconversion-to escapeithrough an overflow-spout; substantially as described.

5. Ihe methodofextractingJnetalvalues i'romsilicious ores, which consists in preheat- .ing such ore, feeding it:,into ,a molten bath. of lo.w-grade matte, -.extrac ti ng values from the oreandpermittingithelresidue of the ore to \fioattoa-point of-dischaigeinto, a separating vessel; substantiall as described.

6. llhe =method o extracting metal values tromsiliciousl-ores, which consists =in;.'preheat ing suchore, dropping .it intov a molten-bath of ilcw grade matte, extracting values Efrem thecre and permitting the residueof the ore toescape-with slag and'matteinto a separatjug vessel at a lower level; substantially as described.

7. The :methodofextrac'ting metal values fromsilicious ores, which consists in preheat ing-suchore, feeding it into. a :molteni-bath of low-grade matte, .ext-tacting values tromlthe ore andpermitting the residue of the ore to escape with slag-and matte into a separating -vessellat a lower level'and to float with slag over a bodyofmatte to a,point of discharge;

substantially as described.

8. The method of extracting metal values from siliciousores, which consists .in feeding such ore into a molten bath of low-grade matte, extracting valuesfrom the ore, and permitting the residue .of the ore to .escape with slag and matte into a separating vessel 'at a lower leveland to float with slagover a body of low grade matte to ,a point of discharge and maintaining in the separating vessel a practically airtight congealed slag covering; substantially as described.

'9. The methodofl extracting metal Values fromsiliCious ores, which consists in'feeding such vore into a molten bath of low-grade matte at one'end of a conyerting vessel, per- .mittin the ore to float while-subjected to the heat 0 conversion-tea point of dischargeat the other, end of the vessel, subjecting the sur- "facezof the'molten bath to; the influence of hot gases .throughout the length of 'theirtravel, extracting values from the ore and permit ting-the residue of the ore to drop with molten gmatteand slag through an untra ped overflow-spout into: a separating vesse at a lower (level, through a practically air-tight dropvtube thatexcludes the chill of ,the atmosphere-and thereafter-permitting such residue jtosfloat over a-bodyl-or lo wgr ade matte in the forehearth to "a point of discharge under- .neath a-. chilled slag covering that will mainvtain-the heat and the fluidity of the bath, untilthe worthless slag-and silica shells of the liquated ore aredischarg d, substantiallyas described.

:10. The method .of liquating ores, which (consists in feeding them ,into a vmolten bath of matte, creating :and maintaining heat by ublowing an air-blast into the matte and providing a. discharge for the ,fused and unfused material substantially as described.

:11. The method of liquating. ores on a moltenbath' of .matte which consists in feeding bre onto the matte, allowing the fused ,andunfused ore .todischarge after it has'revmained in contact. with the molten vbath a suflicientlenigith of-time to liqua'te the values fromrthe nnsed;p0rtions; substantially-as described. 4 c

4 12. fllhe-method ofliquatingores on a molten bathofimatte,whichconsists in blowing :air into therbath feedingore onto the matte thatcontains more silica than can be fluxed .bytthe'ir'on that is setiree-from the matte throughtheaction of .the blast of air, and ,disch'argim; the unfused portions after .hav- .ing :remain'ed tin the furnace a sufficient length-of ,time .to become liquated; substantially asldescribed.

highly silicious ores which consists in feeding the ore onto a body of molten matte, blowing produced to flow with the matte and liquatmg the suspended and unfused pieces of ore prior to their discharge with matte and slag;

substantially as described.

14. The method of liquating ores which consists in extracting their values by subjecting them to the heat produced by the conversion of matte, permitting them to float from one end to the other of an elongated vessel containing the matte, and during such travel liquefying the contained values and a portion of. the slag-making materials and dischargim them from the converting vessel before al of the gangue of the ore is fused; substantially as described.

15. The method of liquating ores which consists in extracting the values from such as contain matte-makin material or precious metals by subjecting them to the heat derived from the oxidation of oxidizable com pounds of metal, until sufiicient acids havecombined with the bases to form a fusible slag and permitting the excess of the acids to discharge in an unfused state with molten slag and matte; substantially as described.

16. The method of liquatingores which consists in supplying to a furnace sufficientoxidizable compounds of metal to maintain a liquid bath of matte, blowing air into the molten bath, feeding onto it orescarrying more acid than base, permitting these materials to remain in the vessel for a sufficient time to enable the acid in the ore to combine with the oxids of the bases ,to form a liquid slag and discharging the excess of silica in an unfused condition with molten slag and matte; substantially as described.

17. The method of liquating ores which consists in separating the bases from the acids by means of heat without perfect fusion of all the acids, su j ecting the raw ore to the oxidizing action of the converting-blast in a converting-furnace, fusing all the matte-making material it contains and a sufficient amount of the slag-making material contained in the ore to permit the fused portions to hold the unfused portions in suspension and to float them through the values from ores by li roducing aoverflow-spout out of the vessel; substantially as described.

18. The method of extracting mineral nation, which consists in providing a bath 0 low-grade matte in a suitable furnace, blowin air thereinto,forming a union of a portion of slag-making material with a portion of the acids through the heats of oxidation, discharging the slag and unfused liquated ores together with any matte which is formed in excess of the amount required to keep the vessel full to the overflow-spout and dischargingthese together into a forehearth for separation; substantially as described.

the bases and other 6o 19. The method of liquating ores which consists in maintaining a continuous bath of low-grade matte in a converter, feeding silicious ore thereinto in excess of the amount that will flux with the matte, and removing the slag as it is melted and the unfused excess silica as it is liquated; substantially as described.

20. The method of liquating ores which consists in providing aconverting-furnace with a bath of low-grade matte, blowing air thereinto, producing heat thereby, feeding ore'onto the surface of the molten bath at one end of the vessel in excess of the portion that can be melted through the formation of selective slags, permitting the molten slag, matte and silicious liquated shells to overfiow continuously into a forehearth at a lower level for separation by gravity, whereby the molten slag and the silicious-ore shells are discharged from the surface of the matte-bath so rapidly by the action of gravity and-by the agitation produced by the entering blast that the ore charges on entering the vessel are insured an intimate, instantaneous and a continuous contact with the lowrade, fiery, corrosive matte from the time 0 their entrance into the vessel to the time of their discharge through an overflow-spout into the forehearth for subsequent separation by gravity; substantially as described.

In testimony whereof I have hereunto set my hand.

. RALPH BAGGALEY. 

